WELCOME

ADANI POWER MAHARASHTRA LTD,TIRODA,

5 X 660 MW

TOPIC- STEAM BLOWING

By- Operation Team

INTRODUCTION
PURPOSE :

Steam
blowing
of
MS
lines,
CRH,HRH,SH,RH,HP & LP bypass pipe
lines of turbine is carried out in order to
remove welding slag, loose foreign
materials, iron pieces, rust etc. from the
system, generated during manufacturing,
transportation & erection.

EFFECT OF BLOWING
DEPENDS ON
1) Thermal shock
2) Removal force of steam
3)
Cleaning force of steam

REMOVAL FORCE OF STEAM

Blowing Mass Flow ,
Q flow= 1.25 * Qmcr (Vmcr /Vblow)
Qmc= mass flow at MCR
Vmc= velocity at MCR
Vblow=blowing velocity

CLEANING FORCE OF
STEAM
The necessity to create in the system, the
steam velocity greater than that is possible
at MCR condition is obvious. These two
velocities are expressed as a ratio
Cleaning factor or Distribution factor
or Cleaning Force Ratio denoted by X or
K.

CLEANING FORCE REQUIRED

(CFR)
OR DISTRIBUTION FACTOR

a) K=Velocity of steam during blowing / Velocity of steam at

MCR
b) K= (Steam flow during blowing) 2 *(Sp.vol of steam at
blowing
(Steam flow at MCR) *
( Sp.vol of steam at
MCR)
Steam flow can be measured by the net feed water flow
CFR & velocities of the steam should be verified to avoid
Over Blowing
The recommended value K > 1.25 ( between 1.25 and 1.4)

PRECONDITIONS FOR STEAM LINE

BLOWING
1) Chemical cleaning should be completed
2) SH primary and secondary de-superheater

3)

4)
5)
6)
7)

piping and RHs emergency de-superheater

piping ready for operation
All permanent piping & temporary piping
insulated and supports/hangers are released
with cold setting
Silencer should be connected at temporary
pipe exit
Soot blowing for APH should be available
Make up for deaerator made ready
Motor Driven BFP with all controls made ready

PRECONDITIONS
7) Hydraulic test of the following lines
completed:
Feed Lines
MS, HRH, CRH Lines
MS to Aux. PRDS Line
All other auxiliary lines identified for
steam blowing
8) Sampling system made ready

PRECONDITIONS
9) Boiler auxiliaries proved serviceable and
ready after pilot operation like:
- Fuel oil system
- Compressors & Atomizing steam system
- Start-up system ( for continuous system)
- Coal Mill system (for continuous system)
- CHP readiness
- Economizer hopper and bottom ash hopper
and its evacuation system (for continuous
system)

PRECONDITIONS
10) All safety valve disc installed after removing
hydro-static plug in drum(sub-critical),
superheaters and reheaters
11) Adequate communication between control
room, boiler and TG area ensured.
12) Flow nozzle, control valves and NRV flaps
wherever applicable should be not erected
before steam blowing and suitable spool
pieces are erected. Strainers in the path
should be removed.
13) Required number of Target Plates and
holder made available

CHEMICAL CLEANING
PROCESS
BOILER FRONT SYSTEM ALKALINE FLUSHING
Mass Flushing
Hot water Rinsing
Alkaline Flushing
Hot DM water Rinsing

MAIN BOILER SYSTEM ACID CLEANIG

Super Heater Filling
Mass Flushing
Alkaline Flushing
Hot DM water Rinsing
Acid Cleaning
Passivation

CHEMICAL CLEANING
ACID CLEANING ( BY CITRIC ACID METHOD )will be done

by circulation method for effectiveness of the cleaning

process.
Acid cleaning will be followed by PASSIVATION, so that the

uniform protective coating of GAMMA FERRIC OXIDE is

formed on the metal surface and corrosion / oxidation
damage to metal surface is prevented and continue during
normal operation by dosing oxygen. The gamma ferric Oxide
formed by using the chemical 1-2 % sodium Nitrite(NaNO2)

BASIC TECHNIQUE USED

1) PUFFING METHOD
2) PURGING METHOD / CONTINEOUS BLOW

METHOD

PUFFING METHOD
To give a thermal shock to the contour being

purged, to dislodge the scale etc.

Procedure: Raise the boiler pressure to a predetermined value (40-60 kg/cm2), shut off
firing and at the same time open the quick
opening valve(EOTV), thus allowing the steam
to escape to atm. with high velocity carrying
with it the loose debris.

PRECAUTION
The Pressure drop

allowed in drum is
limited to
corresponding
saturation temp.
change of 40 OC.

SCHEME
Steam blowing done in stages
Stage-1(a)- SH, MSL, ESV, temporary lines
from ESV to EOTV, EOTV to CRH line, CRH lines
upto boiler end with temporary exhaust pipe.

Tap off lines from CRH to deaerator,

auxiliary PRDS, HP heater 6a & 6b, gland
sealing, etc. shall be remain closed/isolated.

stage 1a end point will be concluded by

observing the indents on the target plate.

STAGE- 1(a)

STAGE- 1(b)
SH,MSL, HP bypass inter connection, hand

operated valve mounted in place of HP bypass

valve and CRH lines upto Boiler end with
temporary exhaust piping.
In this stage 6 to 8 blows will be given through
HP bypass lines to ensure cleanliness of the
limb.
Boiler MS stop valve will be used for stage 1b.
EOTV will be kept closed. Manually Operated
Isolation Valves in HP bypass lines will be kept
opened fully.

STAGE- 1(b)

STAGE-2(a)
1a plus reheater, HRH lines , Interceptor

Valve and temporary pipe.

CRH line along with attemperator shall be

welded with reheater before start of

stage 2a. LP bypass lines shall be blanked
during stage 2a. Stage 2a end point will
be concluded by observing the indents on
target plates

STAGE- 2(a)

STAGE- 2(b)
2a upto IV + LP bypass lines with temporary

exhaust pipe.
Stage 2b blowing will be parallel blow in
the path 2a & 2b. LP Bypass blanks shall be
removed for stage 2b. 4 blows will be given
through L.P. Bypass line to ensure cleanliness
of the limbs

STAGE- 2(b)

STAGE-3
Auxiliary Steam Lines covered in steam
blowing are listed below.
3a) Main steam line to Aux PRDS
3b) CRH to Deaerator
3c) CRH to HPH-6.
All auxiliary steam lines will be steam
blown by continuous blowing method

STAGE-4
The following Aux steam lines,

connected to deaerator are steam blown

using auxiliary steam from Aux PRDS
header.
4a)PRDS to Deaerator.
4b)Extraction 4 to Deaerator.
4c) PRDS to Gland steam header.

CONTINEOUS BLOWING METHOD

The initial procedure is same as puffing

method except:
- Continuous firing till the completion of

steam blowing. No need to shut of the

firing during blowing.
- Maintain constant pressure during the blow

Recommended blowing
parameters
Dynamic steam pressure
= 3.5 MPa
MS temp
= 420(not to exceed)
HRH temp
= 480( not to exceed)
Steam flow = 845 TPH
Corresponding Drum pr.
Furnace load 39%

= 40 Ksc

METHOD

- Set the Temporary purging valve, by-pass

valve and drain valve and granulating

device behind the temporary pipes
- Check the tightness, support and

expansion of the temporary system

- Section by section rinse of condensate

water piping, feed water piping and boiler

through the start-up system to CW system

METHOD:
- Circulation begins when Fe+ in the water of

main feed water pipe and separator outlet

will be less than 100 ppm.
- Maintain the circulation flow or start-up flow
at minimum set value
- Start oil firing and raise the temp and press.
according to the cold start-up.
Temp. rise rate of water wall = less than
2OC / min
Temp. rise rate of main steam = 4 ~ 5 OC /
min

METHOD:

- Before MS press reaches 1.0 Mpa , open

the bypass valve of temporary purging

valve to warm the piping with all water
drain valves of the system open.
-The blowing system divided into two
parts
A) Preliminary Steam Blowing
B) Final Steam Blowing

METHOD
PRELIMINARY CLEANING
PORPOSEa)Primary cleaning out sundries and bulky grain
deposited in the RH and main steam system
b)To ensure fastness of supports and hangers
with proper expansion
c)Know well about the operation property of oil
burning system, condensate water and feed
water systems

PRELIMINARRY STEAM
BLOWING

- Start the oil firing with max. rating of 15%

- Control the gas temperature at furnace
-

outlet below 500 OC (max.538 OC )

Raise the SH outlet press to 1.6 1.8 Mpa
with steam temperature around 350 OC.
Open the temporary purging valve for 1520 min to blow in MS system
Maintain K around 0.5.
SH & RH desuperheater water system also
cleaned

FINAL STEAM BLOWING

- Main steam and reheated steam system are
-

purged in series
Start 2-3 coal mills when oil burner hits the
rated firing rate of 15%
Increase the SH outlet press. to 3.5 Mpa.
Maintain the MS temp < 420 OC.
Keep HRH steam temp around 480 OC.
When the steam line blowing parameter
reaches , open the temporary purging valve
gradually and increase the fuel and feed
water volume to sustain parameter stability.

FINAL .

- Establish the MS flow around 40% of the MCR

-

(max.- 50%)
Ensure CFR (K) should be 1.25 to 1.3 for MS
and 1.05 to 1.1 for reheated steam
Blow under this operating condition for 20 to
30 min
Gradually reduce coal firing and close the
purge valve at 0.5MPa .
Remove the target plate and check it
By estimation, target may satisfy the
requirements after 15 to 20 times in-series
purging

- When the steam line temp is above the

sat. temp of MS press, close all drains
and Open the boiler MSSV fully.
- Maintain the press. through controlled
firing
- Insert a reference target
- Check the CFR
- Allow to run for 30-60 min

TARGET PLATE
Generally Stainless steel panel
Target plate set at the first, sixth, ninth, twelfth

purging, thereafter set target for each purging until

purging results qualified .
Width about 8% of the steam vent tubes inner
diameter(ID) and length equal to ID
Brinell hardness < 90
Steam velocity 258 m/sec
Target plates to be introduced just before
steam blowing / light upto be removed soon after
blowing is completed.

ONLINE TARGET PLATE CHANGE

ARRANGEMENT
GLAND PACKING ARRANGEMENT

GLAND PACKING ARRANGEMENT

DEBRIS FILTER

AUX BOILER TO AUX STEAM

HEADER

TDBFP INLET
BOILER

MS LINE

HPBP

HPS
V

TEMPORARY
PURGING
VALVE

HPS
V

CRH LINE

TDBFP-1
SV

TDBFP-2
SV
TEMPORARY LINE
PERMANENT LINE

HP,CRH,REHEATER & HRH

HPSV
1

BOILER
HPBP

HPSV2
CRH LINE
IPSV
1

HRH LINE
IPSV
2

TEMPORARAY LINE
PERMANENT LINE

HP BYPASS TO CRH NRV

HPSV
1

BOILER
HPBP

HPSV2
CRH LINE
IPSV
1

HRH LINE
IPSV
2

TEMPORARAY LINE
PERMANENT LINE

LP BYPASS VALVE INLET

HPSV
1

BOILER
HPBP

HPSV2
CRH LINE

HRH LINE

LPBP

IPSV
1
IPSV
2

TEMPORARAY LINE
PERMANENT LINE

STEAM BLOWING COMPLETION

CRITARIA
At least 2 continuous target plates should

not have ORIFICE GRANULARITY on the

target shall be not larger than 0.8 mm.

CFR should be 1.25 to 1.4

No. of orifice granularity shall not supass

08 nos.

ADVANTAGES
- Required less time for completion of the total

process
- Less time required to normalize the system for
final light-up to synchronisation
- This reduces the reactionary forces on the

temporary pipes
- Stresses on the boiler system are lower

Comparison between Puffing &

Contineous Method
PUFFING METHOD

More time required for

complete steam blowing due

to stage wise blowing(8-10
days)
More time required for stage
wise temporary pipe erection
and shifting of blowing device
No mill required
Quality of cleanliness is better

than continuous process

CONTINEOUS METHOD
Less time required for

completion (3-4 days)

Less time required as

only valves to be
opened for different
systems
Minimum 02 nos. of

mill required
Quality of cleanliness is
slightly less than
Puffing.

Comparison CONTINEOUS

METHOD

PUFFING METHOD
Thermal shock is the

Steam velocity or Removal

driving force of cleaning

More thermal stress on
tube material and sudden
loading on supports
Repeated light-up and
shutdown

force is the driving force

Less thermal stress on tube
material

There is a time gap

between the blows to

make-up DM water
System normalization time
after steam blowing is
more
Silencer use is optional

Light-up only once in the

beginning of the steam

blowing
DM water make-up to the
system during steam
blowing is a challenge
System normalization time
after steam blowing is less.
Silencer use is compulsory.